Spring System for Hot Tub Cover

ABSTRACT

One example of this application provides the only portable hard cover (hot tub cover) on the market. One example of this application provides 2 caps per molding (instead of one cap). These are big advantages for consumer and reducing manufacturing cost. Different variations have been presented here, as well. In one application, we introduce a new hinge (and the related system) for the hot tub cover. In one example, the cover is too heavy. To remedy this, we have developed a spring lever that can be used for hard covers of various sizes and weights, because we can put different strength springs inside, to compensate for the weight differences, in different situations. This is much safer and easier for the user.

RELATED APPLICATIONS

This application is a CIP of (related to) another copending U.S. application Ser. No. 13/098,467, filed earlier, 1 May 2011, with the same assignee and inventor, which is a CIP of (related to) another U.S. application Ser. No. 12/885,512, filed earlier, 19 Sep. 2010, with the same assignee and inventor. The teachings of both parent (above) cases, including all Appendices, are incorporated herein by reference.

BACKGROUND OF THE INVENTION

One embodiment of this invention provides a method for manufacturing, and the corresponding product, for a hot tub cover. The rotational molding process has been used in the prior art, for the manufacturing process, resulting in one cap per molding. However, in one embodiment of this invention, as shown here, we get 2 caps per molding (instead of one cap), resulting in more efficient way of molding and manufacturing, less expensive manufacturing, and less expensive hot tub cover, which is a big advantage.

One embodiment of this invention provides the only portable hard cover (hot tub cover) on the market. The hard cover is generally more protective as a cover for the hot tub, than a conventional soft cover. Being portable makes it easier to move around, and also, makes it more versatile to fit different hot tubs from different manufacturers, effectively, making it less expensive to manufacture, due to the economy of scale and a larger number of sales and production.

In one embodiment, we introduce a new hinge (and the related system) for the hot tub cover. In one embodiment, we introduce a new spring system for ease of use and safety of the user.

The following patents represent some of the prior art: U.S. Pat. No. 4,857,374; U.S. Pat. No. 6,112,340; U.S. Pat. No. 6,859,952; U.S. Pat. No. 5,974,599; U.S. Pat. No. 6,634,036; and U.S. Pat. No. 6,842,917. In addition, Watkins et al (U.S. Pat. No. 5,398,350 and U.S. Pat. No. 5,428,849 and U.S. Pat. No. 5,685,031) teach portable spa cover, portable SPA, and portable spa cover. Ziebert et al. (U.S. Pat. No. 6,112,340) teaches hot tub and SPA cover.

SUMMARY OF THE INVENTION

One embodiment of this invention provides the only portable hard cover (hot tub cover) on the market. One embodiment of this invention provides 2 caps per molding (instead of one cap). These are big advantages for consumer and reducing manufacturing costs. In one embodiment, we introduce a new hinge (and the related system) for the hot tub cover.

In one embodiment, the cover is too heavy, and thus, it gets slammed shut so hard that it could injure someone. To remedy this, we have developed a spring lever that can be used for hard covers of various sizes and weights, because we can put different strength springs inside, to compensate for the weight differences, in different situations. The result of this addition is that the cover closes with much less force or momentum (or energy), thus, being much safer for the user. It can also be lifted easier by the user.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows one embodiment of the invention, with a portable hard cover.

FIG. 2 shows one embodiment of the invention, with a portable hard cover, from side view, internal.

FIG. 3 shows one embodiment of the invention, with a portable hard cover, from side view, with the cover in the open position.

FIG. 4 shows one embodiment of the invention, with a portable hard cover, with a cross section close-up view.

FIG. 5 shows one embodiment of the invention, with spiral/clock spring method/system.

FIG. 6 shows one embodiment of the invention, with spiral/clock spring method/system.

FIG. 7 shows one embodiment of the invention, with spiral spring method/system.

FIG. 8 shows one embodiment of the invention, with coil spring method/system.

FIG. 9 shows one embodiment of the invention, with coil spring method/system.

FIG. 10 shows one embodiment of the invention, with coil spring method/system.

DETAILED EMBODIMENTS OF THE INVENTION

There are a lot of patents and prior art/ products in the market for hot tub covers. However, we present here the only portable hard cover (hot tub cover) in the market, with 2 caps per molding (instead of one cap), during our manufacturing process.

In one embodiment, we use a conventional cover lifter mechanical system for removing hot tub covers, as shown in the figures, as an example, e.g. using a motor, chain, pulley, cable, lever, rod, railing, or a similar mechanism.

In one embodiment, we present a rotationally-molded hot tub cover with single-walled construction, which allows for a much easier method of construction and saves a lot of money for consumers. A double-walled cover completely encapsulates the foam, whereas we are basically making a “cap” that goes over the top of the foam, to protect it from the elements. With a single-walled construction, we can more efficiently mold and assemble the cover, for cost savings. In summary, we have a rotationally-molded cap with a foam core that is covered with a waterproof material, to keep it from absorbing water. These are mechanically attached to the inside of the roto-molded cap.

There has never been a rotationally-molded hard cover that can be fitted to spas after the SPA has already been manufactured, or in other words, sold on the aftermarket. The reason is that, in the past, these covers have been manufactured specific to a spa model that they were made for, and actually, they were attached to, at the factory. One either buys a hot tub with the integrated hard cover on it (that it was designed for, at the time of the purchase), or one can never get one later.

In one embodiment, our product does not mechanically attach, or require any permanent moldings or brackets on the tub, and therefore, it can be put on any tub. A typical prior art product (e.g. shown in Appendix FIGS. 5-8) has a doubled-wall, rotationally molded cover, with the permanent attachment that must be done at the factory.

In one embodiment, our rotationally-molded hard cover is single-walled, has a cover lifter attachment (similar to the other prior art spas), but it is the only hard cover with a portable cover system in the market. Our lift system (that is incorporated as a part of our cover) is not permanently attached, and therefore, it can fit on any spa. This gives us the ability to sell hard covers to people who already have purchased hot tubs and want a cover or a new/ replacement cover. The other hard covers on the market cannot do this. Only soft vinyl covers have been able to accomplish this in the past.

Additionally, the single-walled construction is a superior method of manufacturing, in that it reduces manufacturing costs, making the product more affordable. The double-walled hard covers cost much more to manufacture.

Note that there are several companies that advertise “hard” covers (as opposed to a thin plastic, bubble wrap type cover), but they are just the vinyl covered styrene covers (i.e. soft covers).

Another way to describe the uniqueness of the cover is that it is the only portable hard cover, not just because it does not permanently attach, but also, because with the other hard covers, the bottom is shaped in such a way that they are form-fitted just for that model of spa. However, our cover, having a soft bottom (due to the fact that it is not doubled-walled) will conform to almost any hot tub that has roughly the same overall length and width dimensions, making it very flexible and versatile.

Here are some of the prior art shown in the figures, for comparison: Appendix FIG. 5 shows a spa with a portable cover lifter (not permanently attached) and a soft vinyl cover. (In one embodiment, we are using a lifting system just like the one shown here.) Appendix FIG. 6 shows a spa with a permanent cover lifter attached, with a soft vinyl cover. Appendix FIG. 7 shows an example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter. Appendix FIG. 8 shows another example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

FIG. 1 shows one embodiment of the invention, with a portable hard cover (e.g. integrated hard cover and cover lifter). Here are the items/features shown in the figure:

-   -   110: Hard Cover     -   112: Ring, Strap, or hinge     -   114: Axel, center rod     -   116: Arm to Axel fastener     -   120, 121: Arm brackets     -   122, 123: cover pieces     -   130: Base support with paddles (that go under the hot tub, for         example). In that configuration, the but tub weight supports         rotational moment from the arm brackets, due to the weight of         cover, when in open position.     -   132: arm bracket, pivoting on the base support     -   134: Pin stopper(s), for example, for limiting the movement of         the arm bracket beyond the allowed open (or closed) position(s).         One or more pins can be used optionally for open or closed         position(s).     -   140: cover flips open     -   142: arm brackets rotate back

FIG. 2 shows one embodiment of the invention, with a portable hard cover, from side view, internal. Here are the items/features shown in the figure:

-   -   210: Hard Cover, e.g., polyethylene skin (e.g., ⅛ inch thick)     -   214: Axel, center rod     -   220: Arm bracket     -   222, 223: filler material, e.g., Sealed foams     -   224, 225: Flaps (e.g. vinyl), for example, riveted inside poly         skin, covering the side of the cover pieces.     -   230: Mounting plate with paddle.     -   232: arm bracket, pivoting on the mounting plate     -   234: Pin stopper(s), for example, for limiting the movement of         the arm bracket beyond the allowed open (or closed) position(s).

FIG. 3 shows one embodiment of the invention, with a portable hard cover, from side view, with the cover in the open position. Here are the items/features shown in the figure:

-   -   300: hot tub side view     -   301: bottom of hot tub     -   314: Axel, center rod     -   320: Arm bracket     -   322, 323: hard cover pieces     -   330: Mounting plate with paddle (that goes under hot tub, for         example). In this configuration, the but tub weight supports         rotational moment from the arm brackets, due to the weight of         cover, when in open position.     -   332: arm bracket, pivoting on the base support     -   334: Pin stopper(s), for example, for limiting the movement of         the arm bracket beyond the allowed open (or closed) position(s).     -   342: arm brackets rotate back, for hot tub cover to get in the         open position

FIG. 4 shows one embodiment of the invention, with a portable hard cover, with a cross section close-up view. Here are the items/features shown in the figure:

-   -   410: Hard Cover, e.g. Single-walled roto-molded polyethylene     -   422: Filler material, e.g., polystyrene, polyurethane, expanded         polystyrene, polyethylene foam, or similar material     -   424: Flap (e.g. vinyl or rubber), or similar material     -   426: Attachment screws, rivets, and/or adhesive glue     -   428: Protective material, e.g., water resistant material.

The hot tub area can be of any size (as one embodiment), to accommodate one or more individuals, however, at a typical, lower range/ dimensions, it can be 4′ to 10′ in length, 29″ to 6′ in height, and 4′ to 9′ in width. However, the sizes mentioned here are typical ranges for some embodiments, as examples, and the invention covers any size, big or small.

The material of our system may comprise one or more of the following: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material (embedded with e.g. water pipes or heater wires), hollow material, or reinforced material (e.g. with metal bar, fabric, or mesh).

The shape of our tub may be one or more of the following: oval, rectangle, square, straight, curved, circular, multiple cross sections, or single cross section, comprising one or more of the following: multiple jets, single jet, multiple flows, single flow, with flow meter, cleaning/filtering mechanism, light, underwater light, dancing light monitored by a computer, with music synchronization, multiple lights, gradual changing lights, rainbow lights, lasers, or any combination of the above.

Here are more descriptions and examples/ embodiments of our invention, using figures and Appendix figures to illustrate:

Appendix FIG. 5 shows a spa with a portable cover lifter (not permanently attached) and a soft vinyl cover. (In one embodiment, we are using a lifting system just like the one shown here.)

Appendix FIG. 6 shows a spa with a permanent cover lifter attached, with a soft vinyl cover.

Appendix FIG. 7 shows an example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

Appendix FIG. 8 shows another example of a double-walled, hard, rotationally-molded cover, with a permanently-attached cover lifter.

Appendix FIG. 9 shows an embodiment of the hinge system.

Appendix FIG. 10 shows an embodiment of the hinge system, with the cover in 2 sections, with short vertical lips around the cover, and belts or extensions attached to the lips.

Appendix FIG. 11 shows an embodiment of the hinge system, in an open position, with one section folded back on the second section.

Appendix FIG. 12 shows an embodiment of the hinge system, installed on a tub, in a closed position, from the side view.

Appendix FIG. 13 shows prior art with different cover structure.

Appendix FIG. 14 shows prior art with different cover structure.

Appendix FIG. 15 shows an embodiment of the hinge system, in the closed position, with 2 sections, and a handle or bar on one side or both sides, for opening or closing operation, as an addition or variation to our teaching.

Appendix FIG. 16 shows an embodiment of the hinge system, in the open position, with 2 sections folded on each other, and a handle or bar on one side or both sides, for opening or closing operation, as an addition or variation to our teaching.

Appendix FIG. 17 shows an embodiment of the hinge system, in the fully open position, with 2 sections folded on each other, on the side, vertically, as an addition or variation to our teaching.

Appendix FIG. 18 shows an embodiment of the hinge system, focused for better view, as an addition or variation to our teaching.

Appendix FIG. 19 shows an embodiment of the hinge system, enlarged for better view, for part A, by a factor of 5 to 1 (scaled), as an addition or variation to our teaching.

Appendix FIG. 20 shows an embodiment of the hinge system, in the closed position, with 2 sections, and a handle or bar on one side or both sides, for opening or closing operation, as an addition or variation to our teaching, with a different hinge configuration.

Appendix FIG. 21 shows an embodiment of the hinge system, enlarged for better view, for part B (scaled), as an addition or variation to our teaching.

Appendix FIG. 22 shows an embodiment of the hinge system, in the half-closed position, with 2 sections, folded up, and a handle or bar on one side or both sides, for opening or closing operation, as an addition or variation to our teaching, with a different hinge configuration.

Appendix FIG. 23 shows an embodiment of the hinge system, enlarged for better view, for part C, by a factor of 5 to 1 (scaled), as an addition or variation to our teaching.

Appendix FIG. 24 shows an embodiment of the hinge system, focused for better view, as an addition or variation to our teaching.

Appendix FIG. 25 shows an embodiment of the hinge system, enlarged for better view, for part D, by a factor of 3 to 1 (scaled), as an addition or variation to our teaching.

Appendix FIG. 26 shows an embodiment of the hinge system, enlarged for better view, for part C-C, and also part B-B, by a factor of 5 to 1 (scaled), as an addition or variation to our teaching, from various angles and views, with dimensions to the center of the radius or intersection of the straight walls, from 7 different views.

Please note that for Appendix FIGS. 9-12, the structure is similar to those shown on FIGS. 2 and 4 (or Appendix FIG. 15), but with vertical lips all around, and without the bar or handle for rotation or opening/closing operations. The variations above are different embodiments of the current invention.

The hinge system in this invention also works with other rotomolded hot tub covers that are currently on the market, but are currently using other types of hinge system.

The rotomolded hard covers on the market today split in the middle of the cover, where each half rests on the opposite side of the spa, when the cover is open, as shown above. Our rotomolded cover hinges in the middle, as shown above.

The advantage to the hinge being in the middle is the ability to add a standard cover lifter to the cover. Additionally, the cover moves off to one side of the hot tub (and not two sides), so one can put the hot tub into tighter corners without having to make space for the open cover (smaller foot prints/ space for installation and storage). Also, as one can see from the pictures above, when a standard hard roto cover is opened and is resting on both sides of the tub, it blocks the view of the people sitting in the tub on both sides of the tub, as well, reducing the users' enjoyment.

In another word, all the other rotationally molded hot tub covers on the market today are permanently attached to the sides of the tub, and they separate down the center, so that each half rests on the opposite sides of the hot tub, often creating an obstacle for entering the tub from those two sides. That is, the prior art method for hinging a cover is not an effective use of space in that a hot tub could not be placed snuggly into a corner of a deck or yard that had fencing or a railing that would prevent the opening of the cover. For example, if a customer was designing a space for a hot tub on a deck or in a gazebo, the customer has to make the area larger to accommodate the other (prior art/ conventional) hot tubs, which is very inconvenient or sometimes impossible in a tight real estate (or expensive space, land, deck, or backyard).

On the other hand, our hinge design allows the hard molded cover to be folded over in the middle, then be moved off to the side, and away from the hot tub. This hinge also allows for the integration of a standard cover lifter, so that the cover is easier to manage. In this embodiment, the cover folds over onto itself, then it is pushed off onto one side of the hot tub, where it is supported by the cover lifter.

This hinge mechanism could be used on single-walled or double-walled hard-molded covers. Most conventional vinyl covers are hinged in the middle, but there are not any hard covers hinged this way, because they are generally too heavy for this purpose. In the case where our cover might be large and heavy (when designed for larger hot tubs), the ability to integrate the cover lifter with the hinge eliminates this problem, as it creates a lever, thus making the operation of the cover more manageable.

Please note that he Watkins et al. patents, mentioned above, discuss a “hinged” hard cover, but the hinge is not permanently connected (like ours), and therefore, it detaches like the existing hard covers. The difference between this invention and what is currently on the market is that this invention does not have the permanent arms attaching the cover to the hot tub. Their invention is intended to separate, not fold over. Thus, our invention has distinguishing features, compared to any other solutions out there in the market (or prior art/patent applications filed).

We have shown (in the figures and Appendix figures) the sketches and drawings of some possible ways, as an example, to use springs to reduce/counter the weight of opening the hot tub cover in the first stage, and also reduce the impact of kinetic energy from the cover being closed.

Coil Spring:

The coil spring would be wrapped around the axle, with one end being bent into a hole in the axle, which is fixed to the horizontal cover lifter lever. The other end of the spring would protrude into the cover half and would be situated so that it provides reverse pressure upward, reducing/countering the weight of the half of the cover, which is the cover half that is opened when first opening the cover to remove it from the hot tub. The second stage being when the cover is folded over in half, then, the cover lever mechanism shifts the entire cover off to the side.

Coil/Clock Spring:

The coil spring would be fixed to the horizontal cover lifter shafts with the axle being slid into the middle of the spring, which would have a slot that accepts the bend in the inner coil. In this embodiment, the axle would pivot with the cover half. The cover half is physically attached to the axle, since they move in unison. The coil spring applies reverse pressure on the axle, and thus, the cover half, countering/reducing its effective weight in both opening the cover in the first stage and reducing the kinetic energy, while closing it.

Custom Design Coil Spring:

The custom design coil spring is encased in a housing and float freely on the axle. The housing has threaded receptors that allow the cover to be mechanically attached. Additionally, the housing is designed so that the screws that hold the cover casing and spring coil against the outside of the cover also allow for a reinforcement spar to be incorporated into the cover to give the flexible plastic interior a larger surface area to support the force from the spring. In this case, the coil spring in encased in a housing which prevents it from being accessed by the user, and thus, is safer in preventing people getting pinched by the flexing coils. The housing is more aesthetically pleasing than the open springs, with a lower profile. The spring is interchangeable. So, if a consumer wishes to install a stronger spring, to make the lifting easier, this can be done easily. The housing attaches to the cover in such a way that it more easily allows for attachment of a reinforcement strut, which by putting pressure against a larger surface area of the plastic, it aids in the leverage of lifting the cover half, and helps keep the integrity of the plastic shell and prevent warping of the plastic from the pressure of the spring.

In one embodiment, the hinge sits completely outside of the cover. It interfaces with the cover through 2 drilled holes (per side) with grommets. We use an angled or straight piece of a rust proof metal on the inside of the cover cap, and bolt it through.

Please note that Appendix FIGS. 27-32 correspond to FIGS. 5-10, respectively. Appendix FIGS. 33-34 correspond to spiral springs, with various models and configurations, plus design formulas and examples, used in this invention.

FIG. 5 shows a spiral/clock spring system. Spiral spring moves with axle which is fixed to the cover and the horizontal shaft on the lifter lever device. FIG. 6 shows a spiral or clock spring system. The slotted axle accommodates spring. Cap goes on other side to prevent spring from slipping off. FIG. 7 shows spiral spring fitting into notch in axle, e.g. with slot at 12 o'clock direction and adapter at 5 o'clock direction, and using a cotter pin, as shown in the figure.

FIGS. 1-14 of Appendix Binder-5 show the component and system designs of various options according to the embodiments of this invention.

FIG. 8 shows a coil spring, used to apply reverse pressure on the other direction, to make the lifting of the cover easier for the user, in the first stage of the opening. FIG. 9 shows a coil spring wrapped around static axle. One end is secured by a hole. The other extends into the cover half to apply upward pressure to counter the weight, for lift. The Fig. shows the hole to secure the spring. The metal plate is for holding spring coil end in place and providing more secure area support. FIG. 10 shows a coil spring system, as one embodiment.

Any variations of the teachings above are also meant to be covered and protected by this current application. 

1. A hot tub cover, said hot tub cover comprising: two caps, covering a hot tub; wherein said two caps are made of hard rigid material; a hinge, located between said two caps; wherein a first of said two caps is folded on a second of said two caps; a spiral or clock spring; wherein said spiral or clock spring is located at one end of said hinge, located between said two caps.
 2. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more motors.
 3. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more stopping pins.
 4. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more rods or arms.
 5. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more brackets.
 6. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises multiple hinges.
 7. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more cotter pins.
 8. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more sealed sections.
 9. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more sealed foam sections.
 10. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more mounting plates.
 11. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more paddles.
 12. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more flaps.
 13. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more lips.
 14. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more polyethylene skin sections.
 15. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more rivets.
 16. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more polystyrene, polyethylene, polyurethane, or expanded polystyrene foam sections, pieces, volumes, or containers.
 17. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more single-walled roto-molded sections.
 18. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more attachment screws, rivets, or devices.
 19. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more water-resistant cover sections.
 20. The hot tub cover as recited in claim 1, wherein said hot tub cover further comprises one or more of the following material: plastic, elastic material, wood, alloy, metal, magnetic material, ferromagnetic material, wool, fabric, clothing, porous material, absorbing, non-absorbing material, mixture, combination, smooth material, coarse material, carved material, molded material, transparent, translucent, opaque material, natural, synthetic material, flexible, rigid material, uniform, non-uniform material, embedded material with pipes or heater wires, hollow material, or reinforced material with metal bar, fabric, or mesh. 